Multiscale Simulation of Crack Propagation in Impact-Welded Al₄Cu₉ Alloy Based on Cohesive Zone Model

The fracture behavior of the Al₄Cu₉ intermetallic compound at the interface of impact-welded Cu/Al joints remains insufficiently explored through integrated multiscale modeling and experimental validation. In this study, molecular dynamic (MD) simulations, finite element (FE) analysis implemented in ABAQUS (version 2020) and a cohesive zone model (CZM) were combined with optical microscopy (OM) and scanning electron microscopy (SEM) observations of the interface and crack initiation zones in impact-welded Cu/Al specimens to investigate crack propagation mechanisms under different defect configurations. The experimental specimens consisted of 1060 aluminum (Al) and oxygen-free high-conductivity (OFHC) copper, fabricated via impact welding and subsequently annealed at 250 °C for 100 h. The interfacial morphology and crack initiation features obtained from OM and SEM provided direct validation for the traction-separation (T-S) parameters extracted from MD and mapped into the FE model. The results indicate that composite defects (blunt crack + void) cause a significantly greater reduction in fracture energy and stress intensity factor than single defects and that defect effects outweigh temperature effects within the range of 200-500 K. The experimentally observed crack initiation locations were in strong agreement with simulation predictions. This integrated simulation-experiment approach not only elucidates the multiscale fracture mechanisms of the Al₄Cu₉ interface but also provides a physically validated basis for the reliability assessment and optimization of aerospace Cu/Al welded structures.